Low-cost connectors for inverters and converters and methods of manufacturing and using the same

ABSTRACT

In some embodiments, systems and methods for connector assembly for use with an AC or DC power interface of a power conversion device, such as a converter and an inverter, are provided. The connector assembly can include a circuit board, a power connector, and a pin. The power connector can have a base configured to be secured relative to the circuit board and define a first channel extending through the power connector along a first channel axis. The first pin can have a first pin body that extends along a first pin axis and a first connection element that extends along the first pin axis from the first pin body to a first terminal end that is skewed relative to the first pin axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/929,553, titled “Low-Cost Connectors for Inverters and Converters andMethods of Manufacturing and Using the Same” and filed on Nov. 1, 2019,which is hereby incorporated by reference in its entirety for allpurposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

This invention was made with government support under DEEE0008350awarded by the U.S. Department of Energy. The government has certainrights in this invention.

BACKGROUND

Photovoltaic modules can generate direct current (DC) power based onreceived solar energy. Photovoltaic modules can include multiplephotovoltaic cells that can be electrically coupled to one another toallow the multiple photovoltaic cells to contribute to a combined outputpower for the photovoltaic module. In some applications, the DC powergenerated by a photovoltaic module can be converted to alternatingcurrent (AC) power through the use of a power inverter, such as aphotovoltaic (PV) microinverter. The power inverter can be electricallycoupled to an output of the photovoltaic module. Often the powerinverter is connected to adapters and intervening wiring.

SUMMARY

In accordance with some embodiments of the disclosed subject matter,systems and methods for establishing electrical connections with powerconversion devices (e.g., inverters and converters) are provided.

In accordance with some embodiments of the disclosed subject matter, aconnector assembly configured for use with at least one of an AC and aDC power interface of a power conversion device, such as an electronicconverter or inverter (e.g., microinverter), is provided. The connectorassembly can include a circuit board, a power connector, and a firstpin. The circuit board can define a first surface and a second surfacespaced apart from the first surface by a thickness. The power connectorcan have a base configured to be secured relative to the circuit boardand define a first channel that extends through the power connectoralong a first channel axis. The first pin can have a first pin body thatextends along a first pin axis and a first connection element thatextends along the first pin axis from the first pin body to a firstterminal end that is skewed relative to the first pin axis. The firstpin can be at least partially seated in the first channel. The terminalend can be configured to electrically engage the circuit board.

Some embodiments include a method for producing a power conversiondevice, such as an electronic converter or inverter. The method caninclude providing a printed circuit board that is configured to receiveelectrical components. The method can include inserting a pin having aconnection element into a channel of a power connector. The method caninclude securing the power connector to the printed circuit board via asecuring portion of the power connector. The method can includeelectrically coupling the connection element to the printed circuitboard. The method can include inserting the printed circuit board intoan interior volume of a housing that includes a cutout so that the powerconnector extends through the cutout.

In some embodiments, a power conversion device, such as an electronicconverter or an electronic inverter (e.g., a microinverter), isprovided. The power conversion device can include a housing, a circuitboard, a DC power connector, and an AC power connector. The housing candefine an interior volume that includes an exterior surface. The circuitboard can be secured within the interior volume. The DC power connectorcan include a DC power connector body and a DC power pin. The DC powerconnector body can be engaged with the housing and the DC power pin canextend through the exterior surface of the housing and into the interiorvolume whereat the DC power pin is coupled to the circuit board. The ACpower connector can include an AC power connector body and an AC powerpin. The AC power connector body can be engaged with the housing and theAC power pin can be coupled to the circuit board.

BRIEF DESCRIPTIONS OF THE DRAWINGS

Various objects, features, and advantages of the disclosed subjectmatter can be more fully appreciated with reference to the followingdetailed description of the disclosed subject matter when considered inconnection with the following drawings, in which like reference numeralsidentify like elements.

FIG. 1 is a top view of a conventional microinverter.

FIG. 2 is an exploded isometric view of a microinverter according to anembodiment of the invention.

FIG. 3 is a back isometric view of a DC power connector of themicroinverter of FIG. 2 .

FIG. 4 is a front isometric view of the DC power connector of FIG. 2 .

FIG. 5 is an isometric view of a first pin of the DC power connector ofFIG. 2 .

FIG. 6 is an isometric view of a second pin of the DC power connector ofFIG. 2 .

FIG. 7 is a cross-sectional isometric view of the DC power connectortaken along line 7-7 of FIG. 4 .

FIG. 8 is an isometric partial view of the DC power connector engagedwith a circuit board of the microinverter of FIG. 2 .

FIG. 9 is an isometric view of an AC power connector of themicroinverter of FIG. 2 .

FIG. 10 is an isometric view of a connector pin of the AC powerconnector of FIG. 9 .

FIG. 11 is a cross-sectional isometric view of the AC power connectortaken along the line 11-11 of FIG. 9 .

FIG. 12 is an isometric partial view of the AC power connector engagedwith the circuit board of the microinverter of FIG. 2 .

FIG. 13 is an exploded front isometric view of the AC power connector ofFIG. 9 and an AC power interface.

FIG. 14 is an exploded rear isometric view of the AC power connector andthe AC power interface of FIG. 13 .

FIG. 15 is a partially exploded isometric view of the AC power interfaceof FIG. 13 .

FIG. 16 is a rear isometric assembled view of the AC power interface ofFIG. 13 .

FIG. 17 is a rear isometric view of an interface body of the AC powerinterface of FIG. 16 .

FIG. 18 is cross-sectional top view of the interface body taken alongline 18-18 of FIG. 15 .

FIG. 19 is an isometric view of an interface pin of the AC powerinterface of FIG. 13 .

FIG. 20 is an exploded bottom isometric view of the microinverter ofFIG. 2 and the AC power interface of FIG. 13 secured to a rail.

FIG. 21 is a top view of the microinverter engaged with the rail of FIG.20 .

FIG. 22 is an exploded isometric partial view of components of amicroinverter according to another embodiment of the invention.

FIG. 23 is a front isometric view of a DC power connector of themicroinverter of FIG. 22 .

FIG. 24 is a rear isometric view of a DC power connector of themicroinverter of FIG. 22 .

FIG. 25 is a cross-sectional isometric view of the DC power connectortaken along line 25-25 of FIG. 23 .

FIG. 26 is an exploded isometric view of components of the microinverterof FIG. 22 .

FIG. 27 is cross-sectional isometric partial view of components of themicroinverter of FIG. 22 .

FIG. 28 is an exploded partial front view of the microinverter of FIG.22 .

FIG. 29 is an assembled partial front view of the microinverter of FIG.28 .

FIG. 30 is an assembled side view of components of the microinverter ofFIG. 22 .

FIG. 31 is a top view of the DC power connector engaged with a circuitboard of FIG. 22 .

FIG. 32 is a bottom view of the DC power connector engaged with thecircuit board of FIG. 31 .

FIG. 33 is an isometric view of a pin according to some embodiments ofthe invention.

FIG. 34 is a side view of the pin of FIG. 33 .

FIG. 35 is an isometric view of a first single DC power connectoraccording to some embodiments of the invention.

FIG. 36 is an isometric view of the first single DC power connector ofFIG. 35 .

FIG. 37 is an exploded isometric view of the pin of FIG. 33 and thefirst single DC connector of FIG. 35 .

FIG. 38 is an exploded isometric view of the first single DC powerconnector of FIG. 35 , a second single DC power connector, and ahousing.

FIG. 39 is an assembled isometric view of the first and second single DCpower connectors and the housing of FIG. 38 .

FIG. 40 is an isometric partial side view of the housing and the firstsingle DC power connector of FIG. 39 engaged with a circuit board.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled,” and variationsthereof, are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

Also as used herein, unless otherwise specified or limited, directionalterms are presented only with regard to the particular embodiment andperspective described. For example, reference to features or directionsas “horizontal,” “vertical,” “front,” “rear,” “left,” “right,” and so onare generally made with reference to a particular figure or example andare not necessarily indicative of an absolute orientation or direction.However, relative directional terms for a particular embodiment maygenerally apply to alternative orientations of that embodiment. Forexample, “front” and “rear” directions or features (or “right” and“left” directions or features, and so on) may be generally understood toindicate relatively opposite directions or features.

The following discussion is presented to enable a person skilled in theart to make and use embodiments of the invention. Given the benefit ofthis disclosure, various modifications to the illustrated embodimentswill be readily apparent to those skilled in the art, and the genericprinciples herein can be applied to other embodiments and applicationswithout departing from embodiments of the invention. Thus, embodimentsof the invention are not intended to be limited to embodiments shown,but are to be accorded the widest scope consistent with the principlesand features disclosed herein. The following detailed description is tobe read with reference to the figures, in which like elements indifferent figures have like reference numerals. The figures, which arenot necessarily to scale, depict selected embodiments and are notintended to limit the scope of embodiments of the invention. Skilledartisans will recognize the examples provided herein have many usefulalternatives and fall within the scope of embodiments of the invention.

As noted above, inverters, such as microinverters, can be used inphotovoltaics. A microinverter can convert direct current (DC) generatedby a solar module to alternating current (AC). In general, a singlemicroinverter can be in electrical contact with a single solar moduleand can have several advantages over conventional inverters. Forexample, a microinverter can electrically isolate solar modules withinan array of modules from one another so that if there is an issue, oreven complete failure of a solar module, the output of the array is notdisproportionately affected.

In general, AC and DC connectors are among major components in thedevelopment and manufacturing of various power conversion devices, suchas converters and inverters. These connectors can increase the cost ofmanufacturing, assembling, and packaging for power conversion systems.For example, AC and DC connectors often contribute a significant portionof the bill-of-materials for the entire converter/inverter. As brieflydescribed above, in the case of a photovoltaic (PV) microinverter,standard systems incorporate two connectors to operate: a DC connectorto connect the PV module to the inverter, and an AC connector to connectthe inverter to a power grid. Such hardware components can increase thecost of the system. Additionally, AC and DC components can adverselyincrease the size and weight of individual microinverters. Since aplurality of microinverters may be used in an array of solar modules, itmay be useful to reduce the size, weight, and cost of eachmicroinverter, and to enhance the manufacturability of eachmicroinverter by, for example, reducing the cost and the potentialfailure modes.

Generally, some embodiments of the invention can include a device forestablishing electrical connections with power conversion devices, suchas inverters and converters. In some embodiments, a connector accordingto some embodiments of the invention may eliminate the need forstandard, and often costly, cumbersome interface connections between ACbus-cables and AC output connectors of inverter/converter structures,such as a microinverter, for example. Additionally, some embodiments ofthe invention provide methods of manufacturing and using suchconnectors. While the example embodiments are generally described in thecontext of a microinverter, one skilled in the art (given the benefit ofthis disclosure) will appreciate that the scope is not limited to theexample microinverter, but is generally applicable to power conversiondevices and other contexts that can benefit from the concepts taughtherein.

FIG. 1 illustrates an example of a conventional microinverter 100. Themicroinverter 100 includes a housing 102, a DC power connector assembly104, and an AC power connector assembly 106. The DC power connectorassembly 104 can be configured as an adapter and can include DC powercables 108 and a DC power connector 110. Internally within the housing102, though not shown, conventional microinverters often includeadditional wiring to electrically couple DC power cables, such as the DCpower cables 108 illustrated in FIG. 1 , to a printed circuit board. Asa result, during a manufacturing process of the conventionalmicroinverter 100, the DC power connect assembly 104 may be electricallycoupled to the microinverter 100 after the housing 102 is assembled andthe DC power cables fed through openings (not shown) in the housing 102.

Similar to the DC power connector assembly 104, the AC power connectorassembly 106 can be configured as an adapter and include an AC powercable 112 and an AC power connector 114. In some conventionalmicroinverters, such as the microinverter of FIG. 1 , additional wiringmay also be used inside the housing 102 to electrically couple the ACpower cable 112 to a printed circuit board. Like the DC power connectorassembly 104, during the manufacturing process of the conventionalmicroinverter 100, the AC power connector assembly 106 is oftenelectrically coupled to the microinverter 100 after the housing 102 isassembled. Adhesive sealants are sometimes used in an attempt toestablish an environmental barrier where the cables pass into thehousing 102, with limited reliability and effectiveness.

FIG. 2 illustrates one example of an electronic inverter, configured asa microinverter 120, according to one embodiment of the invention. Themicroinverter 120 includes a housing 122, a circuit board 124, a DCpower connector 126, and an AC power connector 128. In the illustratedembodiment, the housing 122 includes a body 130 that defines an interiorvolume and includes an exterior surface 132. The body 130 furtherincludes a first notch 134 and a second notch 136 formed therein. Thefirst notch 134 includes a first protrusion 138 that extends along asurface of the first notch 134. Similarly, the second notch 136 includesa second protrusion 140 that extends along a surface of the second notch136. In the illustrated embodiment, each of the first and second notches134, 136 are formed in a boss that extends from the exterior surface 132generally about the perimeter of the first and second notches 134, 136.

The housing 122 also includes a lid 142 that is dimensioned to engageand be secured to the body 130 via fasteners 144. In the illustratedembodiment, the fasteners 144 are configured as screws. However, otherconfigurations are possible. For example, other fasteners such as pins,bolts, nuts, adhesives, etc. can be used to secure the lid 142 to thebody 130. The lid 142 includes a pair of mount arms 146 that extendtherefrom. In the illustrated embodiment, the pair of mount arms 146 aregenerally coplanar with the lid 142. In other embodiments, the housing122 can include additional or alternative mounting features, such asmounting brackets that extend from the body 130.

Still referring to FIG. 2 , the circuit board 124, which can beconfigured as a printed circuit board (PCB), includes a top surface 152and a bottom surface 154. The top surface 152 and the bottom surface 154define a thickness of the circuit board 124, which is an orthogonallength between the top surface 152 and the bottom surface 154. Ingeneral, the circuit board 124 is configured to electrically couple avariety of electrical components of the microinverter 120. For example,the circuit board 124 can include conductive tracks, pads, and otherfeatures etched from one or more sheet layers of copper laminated ontoand/or in between a non-conductive substrate.

Also shown in FIG. 2 , the DC power connector 126 includes a DC powerconnector body 160 and first and second pins 162, 164. The DC powerconnector 126 can be coupled to a corresponding DC power output. Forexample, the DC power connector 126 may be configured to be implementedwith a PV panel. In particular, the DC power connector 126 may beconfigured to be compatible with industry standard connectors, such asan MC-4 connector type, for example. The AC power connector 128 includesan AC power connector body 170 and connector pins 172. The AC powerconnector 128 may be configured to electrically engage to acorresponding AC power interface (see, for example, FIGS. 13 and 14 ),which can be used to connect the microinverter 120 to a power grid. Inone embodiment, the first and second pins 162, 164 (and the pinsdescribed throughout) may be produced from folded and press-formedcopper sheet, or of any other suitable material/process to meetapplication-specific requirements.

FIGS. 3 and 4 illustrate the DC power connector 126 of FIG. 2 . The DCpower connector body 160 includes a first plug 176 and a second plug178. The first plug 176 includes a first channel 180 that defines afirst channel axis. The first plug 176 further includes a pair of arms182 that can be resilient and configured as female connector lockingtabs that extend from a base 184 of the first plug 176. The first plug176 also includes a seal 186, which may be configured as an O-ring,proximate to the base 184. The second plug 178 includes a second channel190 that defines a second channel axis. The second plug 178 furtherincludes a pair of connector receptacles 192 configured as maleconnector tab receptacles.

Still referring to FIGS. 3 and 4 , the DC power connector 126 includes aconnector base 196 having a flat surface 198 and a curved surface 200that extends around the base 196 and connects to the flat surface 198.The curved surface 200 includes a profile that is similarly shaped tothe first notch 134 in the housing 122, and defines a groove 202. Thegroove 202 is dimensioned to receive the first protrusion 138 of thefirst notch 134 formed in the body 130 of the housing 122. Theengagement of the first protrusion 138 with the groove 202 will bedescribed below with reference to FIG. 8 . In other embodiments, a DCpower connector, similar to the DC power connector 126, can include amating feature similar to the groove 202 that can be dimensioned toengage a corresponding mating feature formed in a lid of a housing,similar to the lid 142, to establish a sealing interface completelyabout the base 196.

FIGS. 5 and 6 illustrate the first and second pins 162, 164 of the DCpower connector 126, respectively. With reference to FIG. 5 , the firstpin 162 includes a pin body 208 that defines a first pin axis. The pinbody 208 includes an outer surface 210 and an inner channel 212. Theouter surface 210 includes an annular recessed portion 214 and anannular protruded portion 216. The pin body 208 is generally configuredas a female pin dimensioned to receive a corresponding male pin withinthe inner channel 212. The first pin 162 also includes a firstconnection element 218 extending from the pin body 208 along the firstpin axis.

The first connection element 218 includes a terminal end 220. In theillustrated embodiment, the terminal end 220 is skewed relative to thefirst connection element 218 and relative to the first pin axis. Inparticular, in the illustrated embodiment, the terminal end 220 is bentapproximately 90 degrees relative to the first pin axis. However, inother embodiments, the terminal end 220 can be skewed at any anglerelative to the first pin axis. Additionally, in some embodiments, theterminal end 220 can be substantially collinear with the firstconnection element 218. In other embodiments, the skew in the firstconnection element 218 may occur closer to or further from, forinstance, the terminal end 220.

With reference to FIG. 6 , the second pin 164 includes a pin body 224that defines a second pin axis. The pin body 224 includes an outersurface 226 having a ramped annular protrusion 228 and an annularprotruded portion 230. The pin body 224 is generally configured as amale pin dimensioned to be received in a corresponding female pin withinan inner channel. The second pin 164 also includes a second connectionelement 232 extending from the pin body 222 along the second pin axis.

The second connection element 232 includes a terminal end 234 that issubstantially similar to the terminal end 220 of the first pin 162, andtherefore will not be described in detail. In general, the gauges of thefirst and second connection elements 218, 232 illustrated in FIGS. 5 and6 , respectively, are by way of example. A variety of gauges andcross-sections are possible and can be adjusted, varied, or selectedbased on the use and capabilities of the microinverter 120, currentand/or voltage ratings, circuit board characteristics such as proximityof electrical components or pre-formed recesses, etc. Therefore, thegauges of the first and second connection elements 218, 232 can begreater or less than the illustrated embodiment, and the form factorscan be adapted to address application-specific requirements.

Generally, one of the first pin 162 and the second pin 164 cancorrespond to a positive DC power terminal. Likewise, the other of thefirst pin 162 and the second pin 164 can correspond to a negative DCpower terminal.

FIG. 7 illustrates a cross-sectional view of the DC power connector 126according to some embodiments of the invention. As shown, the first pin162 can be inserted into the first channel 180 of the first plug 176 sothat the first channel axis is collinear with the first pin axis of thefirst pin 162. In the illustrated embodiment, the first channel 180includes a first portion 240 and a second portion 242 separated by astep 244. As shown, the first portion 240 is generally wider in crosssection than the second portion 242.

When the first pin 162 is inserted into the first channel 180 andsecured to the DC power connector body 160, the annular protrudedportion 216 abuts the step 244 and the annular recessed portion 214 isseated within the second portion 242 of the first channel 180. Thesecond portion 242 may include an annular or partial inward protrusionconfigured to interface with the recessed portion 214 of the first pin162 to releasably couple the first pin 162 in the first channel 180. Thefirst connection element 218 extends through the first portion 240 ofthe first channel 180 and outside of the first channel 180 proximate tothe connector base 196. The terminal end 220 is positioned outside thefirst channel 180 and generally extends toward the flat surface 198 ofthe DC power connector body 160. The direction that the terminal end 220extends may be dictated by the connection orientation of the DC powerconnector body 160 relative to the circuit board 124. Therefore, inother embodiments, the terminal end 220 may extend in differentdirections than shown in FIG. 7 , as will be described in detail below.

Still referring to FIG. 7 , the second pin 164 can be inserted into thesecond channel 190 of the second plug 178 so that the second channelaxis is collinear with the second pin axis of the second pin 164.Similar to the first channel 180, the second channel 190 includes afirst portion 250 and a second portion 252 separated by a step 254. Asshown, the first portion 250 is generally wider in cross section thanthe second portion 252.

When the second pin 164 is inserted into the second channel 190 andsecured to the DC power connector body 160, the annular protrudedportion 230 abuts the step 254 and the ramped annular protrusion 228engages a lock member 256 formed in the second portion 252. The rampedannular protrusion 228 can move past the lock member 256 in a firstdirection as the second pin 164 is inserted into the second channel 190,and is inhibited from being unintentionally moved in a second directionout of the second channel 190. Similar to the first connection element218 and terminal end 220, the second connection element 232 extendsthrough the first portion 250 of the second channel 190 and the terminalend 234 extends toward the flat surface 198 of the DC power connectorbody 160.

Each of the first and second pins 162, 164 include elements formed ontheir respective pin bodies 208, 224 that engage the DC power connectorbody 160 to axially orient the first and second pins 162, 164 within therespective first and second channels 180, 190. In some embodiments, eachof the first and second pins 162, 164 can include elements formed ontheir respective pin bodies 208, 224, such as alignment features, forexample, that rotationally orient the pins 162, 164 within therespective channels 180, 190. In particular, an alignment feature (see,for example, FIG. 25 ) can rotationally orient each terminal end 220,234 with respect to the DC power connector body 160 to facilitateelectrically coupling the DC power connector 126 to the circuit board124 during a manufacturing process.

FIG. 8 illustrates the DC power connector 126 electrically coupled tothe circuit board 124 and secured to the housing 122 at the first notch134 formed in the body 130. In an installed configuration, the circuitboard 124 can be secured within the housing 122 so that the bottomsurface 154 of the circuit board 124 faces the body 130 of the housing122. The DC power connector 126 can be secured within the first notch134 so that the first protrusion 138 is seated within the groove 202 ofthe connector base 196 (e.g., forming a tongue and groove-type fit).

When the DC power connector 126 is secured to the housing 122, theinterface between the curved surface 200 of the connector base 196 andthe first notch 134 can include one or more of a seal, sealant, oradhesive. The one or more of the seal, sealant, or adhesive canfacilitate securing the DC power connector 126 to the housing 122 andprovide a barrier between the exterior surface 132 of the body 130 andthe interior volume. Similarly, when the DC power connector 126 issecured to the housing 122, the flat surface 198 can engage the lid 142.The interface between the flat surface 198 and the lid 142 can alsoinclude one or more of a seal, sealant, or adhesive to facilitatesecuring the DC power connector 126 to the housing 122 and provide abarrier between the exterior surface 132 and the interior volume of thehousing 122.

Portions of the first and second connection elements 218, 232 extendbeyond their respective first and second channels 180, 190 of the DCpower connector body 160 (see, for example, FIG. 7 ). In an installedconfiguration, the portions of the first and second connection elements218, 232 that extend beyond the DC power connector body 160 extend underthe circuit board 124 proximate to the bottom surface 154. The circuitboard 124 includes recesses 260 that extend through the thickness of thecircuit board 124. The terminal ends 220, 234 of the first and secondpins 162, 164, respectively, can each extend through a recess 260.During a manufacturing process, the terminal ends 220, 234 can besoldered, crimped, or otherwise deformed at the top surface 152 of thecircuit board 124 to provide electrical coupling between the componentsof the circuit board 124 and the DC power connector 126. In someembodiments, the terminal ends 220, 234 can be electrically coupled tothe circuit board 124 before the circuit board 124 is inserted into thehousing 122, such that the DC power connector 126 and the circuit board124 can be installed into the housing 122 as an assembly.

In general, the first and second connection elements 218, 232 and theirrespective terminal ends 220, 234 provide a rigid connection between theDC power connector 126 and the circuit board 124. In some cases, therigid connection can restrict motion of the first and second pins 162,164 relative to the circuit board 124, which can reduce fatigue failurebetween the terminal ends 220, 234 and the circuit board 124.Additionally, direct connection of the first and second pins 162, 164from the DC power connector 126 and the circuit board 124 can facilitatecompact housing compared to some conventional microinverters that employcables or wires to electrically couple components of a circuit board toa DC power connector. In some cases, eliminating unnecessary wiredconnections between components within a microinverter can save time andcosts (e.g., material and labor costs) during manufacturing processes(e.g., an automated manufacturing process), and reduce potential failuremodes while improving reliability.

In the embodiment illustrated in FIG. 8 , the terminal ends 220, 234extend through the recesses 260 of the circuit board 124 from the bottomsurface 154 to the top surface 152. However, in other embodiments, itshould be appreciated that various components, such as the DC powerconnector body 160 or the first and second pins 162, 164, could berotated 180 degrees so that the terminal ends 220, 234 extend throughthe recesses 260 of the circuit board 124 from the top surface 152 tothe bottom surface 154. In still other embodiments, portions of theconnection elements 218, 232 may extend across a single side of thecircuit board 124 and can be electrically coupled to the circuit board124 on that same side.

FIG. 9 illustrates the AC power connector 128 of the microinverter 120of FIG. 2 . The AC power connector body 170 includes three plug members276. As illustrated, the center plug member 276 includes an irregularouter surface geometry to facilitate appropriate connection orientationbetween the AC power connector 128 and an AC power interface connector.Generally, the three plug members 276 and their corresponding connectorpins 172 correspond to common AC terminals (e.g., line, neutral, andearth). Each of the plug members 276 includes a channel 278 that definesa channel axis. The AC power connector body 170 also includes a pair ofarms 280 that can be resilient and configured as female connectorlocking tabs that extend from a base 282 of the AC power connector body170. The AC power connector 128 also includes a seal 284 proximate tothe base 282.

The base 282 includes a flat surface 286 and a curved surface 288 thatextends around the base 282, similar to the flat surface 198 and thecurved surface 200 of the DC power connector 126. The curved surface 288includes a profile that is similarly shaped to the second notch 136 inthe housing 122 and defines a groove 290. In general, the groove 290 isdimension to receive the second protrusion 140 of the second notch 136.The engagement of the second protrusion 140 with the groove 290 will bedescribed below with reference to FIG. 12 . In other embodiments, an ACpower connector, similar to the AC power connector 128, can include amating feature similar to the groove 290 that can be dimensioned toengage a corresponding mating feature formed on a lid of a housing,similar to the lid 142.

FIG. 10 illustrates one of the connector pins 172 of the AC powerconnector 128. Each of the connector pins 172 can be substantiallysimilar, therefore the description of a single connector pin 172 belowcan apply to each of the connector pins 172. The connector pin 172includes a pin body 296 that defines a connector pin axis. The pin body296 includes an outer surface 298 and an inner channel 300. The outersurface 298 includes an annular recessed portion 302 and an annularprotruded portion 304. The pin body 296 is generally configured as afemale pin dimensioned to receive a corresponding male pin within theinner channel 300. The connector pin 172 also includes a connectionelement 308 extending from the pin body 296 along the first pin axis,similar to the first and second connection elements 218, 232 of the DCpower connector 126.

Similar to the first and second connection elements 218, 232, theconnection element 308 includes a terminal end 310. In the illustratedembodiment, the terminal end 310 is skewed relative to the connectionelement 308 and relative to the connector pin axis. However, in otherembodiments, the terminal end 310 can be skewed at any angle relative tothe connector pin axis. Additionally, in some embodiments, the terminalend 310 can be substantially collinear with the connection element 308.In other embodiments, the skew in the connection element 308 may occurcloser to or further from, for instance, the terminal end 310.

FIG. 11 illustrates a cross-sectional view of the AC power connector 128according to some embodiments of the invention. As shown, the connectorpins 172 can be inserted into their respective channels 278 of the plugmembers 276 so that each connector pin axis is collinear with eachchannel axis. In the illustrated embodiment, each channel 278 includes afirst portion 316 and a second portion 318 separated by a step 320. Asshown, the first portion 316 is generally wider in cross section thanthe second portion 318.

When each connector pin 172 is inserted the respective channel 278 andsecured to the AC power connector body 170, each annular protrudedportion 304 abuts the respective step 320 and each annular recessedportion 302 is seated within the respective second portion 318 of thechannels 278. Each of the second portions 318 may include an annular orpartial inward protrusion configured to interface with the recessedportion 302 of the connector pin 172 to releasably couple the connectorpin 172 in the respective channels 278. Each connection element 308extends through the respective first portion 316 of the channels 278 andoutside of the channels 278 proximate to the base 282. Each terminal end310 is positioned outside the respective channel 278 and generallyextends toward the flat surface 286 of the AC power connector body 170.The direction that the terminal ends 310 extend may be dictated by theconnection orientation of the AC power connector body 170 relative tothe circuit board 124. Therefore, in other embodiments, the terminalends 310 may extend in different directions than shown in FIG. 11 , aswill be described in detail below.

Like the DC power connector 126, some embodiments of the AC powerconnector 128 can include alignment features. Alignment features canrotationally orient each terminal end 310 with respect to the AC powerconnector body 170 to facilitate electrically coupling the AC powerconnector 128 to the circuit board 124 during a manufacturing process.Such alignment features can include ridges, notches, protrusions,recesses, etc. formed in one or both of the AC power connector body 170or the connector pins 172.

FIG. 12 illustrates the AC power connector 128 electrically coupled tothe circuit board 124 and secured to the housing 122 at the second notch136 formed in the body 130. The AC power connector 128 can be securedwithin the second notch 136 so that the second protrusion 140 is seatedwithin the groove 290 of the base 282 (e.g., forming a tongue andgroove-type fit). Similar to the DC power connector 126, when the ACpower connector 128 is secured to the housing 122, the interface betweenthe curved surface 288 of the base 282 and the second notch 136 caninclude one or more of a seal, sealant, or adhesive. The one or more ofthe seal, sealant, or adhesive can facilitate securing the AC powerconnector 128 to the housing 122 and provide a barrier between theexterior surface 132 of the body 130 and the interior volume. Similarly,when the AC power connector 128 is secured to the housing 122, the flatsurface 286 can engage the lid 142, similarly to the flat surface 198 ofthe DC power connector 126.

Like the DC power connector 126, portions of the connection elements 308extend beyond their respective channels 278. The portions that extendbeyond the AC power connector body 170 extend similarly under thecircuit board 124 and engage recesses 260 formed in the circuit board124. Details and alternatives described above regarding the electricalcoupling of the connection elements 218, 232 of the DC power connector126 to the circuit board 122 can be applied to the connection elements308 of the AC power connector 128.

As described above, the AC power connector 128 can be electricallycoupled to the circuit board 124 via the connector pins 172 and securedto the housing 122 of the microinverter 120. Some embodiments of theinvention also include an AC power interface that can be selectivelycoupled to the AC power connector 128. In some embodiments, DC power canbe converted via the microinverter 120 to AC power that can betransferred via contact of the AC power connector 128 and an AC powerinterface.

FIGS. 13 and 14 illustrate an AC power interface 330 according to someembodiments of the invention. The AC power interface 330 includes aninterface body 332, interface pins 334, screw terminals 336, terminalplates 338, and a back plate 340. In general, the AC power connector 128can be configured as a female pin connector dimensioned to engage the ACpower interface 330, which can be generally configured as a male pinconnector.

FIG. 15 illustrates a partially exploded view of the AC power interface330 of FIGS. 13 and 14 . The interface body 332 includes a base 344 thathas a flat surface 346 and a curved surface 348 that extends around thebase 344 and connects to the flat surface 346. The curved surface 348includes a groove 350 formed therein. The base 344 also includes notches352 formed on lateral sides of the interface body 332. The interfacebody 332 further includes a receiving portion 358 that includes channels360 and connector receptacles 362. The channels 360 are dimensioned toeach receive a respective plug member 276 of the AC power connector 128.The channels 360 are also configured to centrally receive the interfacepins 334. The connector receptacles 362 are configured as male connectorreceptacles and can receive a pair of arms, such as the arms 280 of theAC power connector 128, for example.

Referring to FIGS. 15 and 16 , the back plate 340 includes notches 366that correspond to the notches 352 formed in the interface body 332. Asillustrated in FIG. 16 , when the back plate 340 is engaged with theinterface body 332, and the notches 352, 366 are aligned, each of thenotches 352, 366 form holes 370. Each hole 370 can be configured as awire hole. In particular, the holes 370 can be inlet or outlet wireholes, which may be used to daisy-chain several microinverters inparallel, for instance. The back plate 340 generally includes a matingprofile 374 that is dimensioned to engage the interface body 332proximate to the base 344. The back plate 340 can be secured to theinterface body 332 via an interference fit, fasteners, adhesives, etc.to, in some forms, establish a seal between one or more wires passingthrough the holes 370. The back plate 340 and the interface body 332 maybe configured to establish sealing engagement, such as through use of acooperating groove and gasket construction.

FIG. 17 illustrates the base 344 of the interface body 332 with the backplate 340 removed. In general, the back plate 340 provides a coveringfor a portion of the base 344 of the interface body 332. In particular,the back plate 340 can cover the screw terminals 336. The screwterminals 336 are separated by terminal dividers 378 that can reduceunwanted electrical contact between electrical components, such aswires.

As illustrated in FIG. 18 , when the screw terminals 336 are engagedwith the interface body 332, the terminal plates 338 can be sandwichedbetween the screw terminals 336 and the interface body 332. The screwterminals 336 include external threads that are dimensioned to extendinto the interface pins 334 within the channels 360.

FIG. 19 illustrates one of the interface pins 334 of the AC powerinterface 330. Each of the interface pins 334 can be substantiallysimilar, therefore the description of a single interface pin 334 canapply to each of the interface pins 334. The interface pin 334 includesa pin body 382 that defines an interface pin axis. The pin body 382includes an outer surface 384 and an internally threaded channel 386.The internally threaded channel 386 is dimensioned to receive theexternal threads of the screw terminals 336. The outer surface 384includes a ridge 388 that extends parallel to the interface pin axis.The outer surface 384 also includes a ramped annular protrusion 390.

Referring back to FIG. 18 , the ramped annular protrusion 390 isconfigured to engage a lock member 394 formed within the channel 360 ofthe AC power interface 330. The ramped annular protrusion 390 can movepast the lock member 394 in a first direction as the interface pin 334is inserted into the channel 360. Once inserted, the interface pin 334is inhibited from being unintentionally moved in a second direction outof the channel 360 via the ramped annular protrusion 390 engaging thelock member 394.

In some embodiments, the AC power interface 330 can be secured tostructure, such as a beam or a rail. For example, FIG. 20 illustratesthe microinverter 120 and the AC power interface 330 coupled to a rail400. The rail 400 includes a channel 402. The channel 402 is configuredto have wire ran therethrough, which can be electrically coupled to theAC power interface 330. The wire may enter or exit the AC powerinterface 330 at the holes 370 and can be electrically coupled to the ACpower interface 330 via the screw terminals 336. The microinverter 120can then be electrically coupled to the wires via the connection of theAC power connector 128 and the AC power interface 330.

As illustrated in FIG. 21 , the housing 122 of the microinverter 120 canbe secured to the rail 400 via the mount arms 146. In general the mountarms 146 are configured as housing-integrated mounting brackets. Themount arms 146 include mounting apertures 404 through which a fastener(e.g., screws, bolts, etc.) can extend to engage with the rail 400 tosecure the housing 122 to the rail 400. In other embodiments, thehousing 122 can include an interface structure that may be clipped,wedged, clamped, etc. to a supporting structure.

Now that embodiments of the microinverter 120, including the DC powerconnector 126 and the AC power connector 128, have been described above,additional embodiments of the invention will be described below. In thefollowing embodiments, various features and aspects described below canbe applied to embodiments of the microinverter 120, and, in particular,the DC power connector 126 and the AC power connector 128 describedabove. Likewise, features and aspects of the following embodiments belowthat are substantially similar to those of the microinverter 120 will beomitted to avoid repetition.

FIG. 22 illustrates components of a microinverter 420 according to oneembodiment of the invention. The microinverter 420, among othercomponents, includes a housing 422, a circuit board 424, and a DC powerconnector 426. In the illustrated embodiment, the housing 422 includes abody 430 having an exterior surface 432 and a notch 434 formed therein.The housing 422 also includes a lid 436. Each of the body 430 and thelid 436 of the housing 422 are only partially represented in FIG. 22 andthe housing 422 is configured to enclose components of the microinverter420, similar to the housing 122. The housing 422 further includes a seal440 configured as a gasket that can be seated between the body 430 andthe lid 436.

FIGS. 23 and 24 illustrate the DC power connector 426. Like the DC powerconnector 126, the DC power connector 426 includes a first plug 446 anda second plug 448 that extend from a base 450. The base 450 includes aflat surface 452 and a curved surface 454 that extends around the base450 and connects to the flat surface 452. The curved surface 454includes a profile that is similarly shaped to the notch 434 in thehousing 422 and defines a groove 456. The flat surface 452 includes achannel 458 that intersects the groove 456. The channel 458 isdimensioned to receive the seal 440 when the DC power connector 426 issecured to the housing 422 and the lid 436 is secured to the body 430.

With reference to FIG. 24 , the base 450 also includes a securingportion 466 that extends from the base 450 in a direction opposite thefirst and second plugs 446, 448. The securing portion 466 includesprotrusions 468 that extend generally perpendicular from a mate surface470 of the securing portion 466. The mate surface 470 is generallyparallel to channel axes that are defined by the first and second plugs446, 448. In one embodiment, the mate surface 470 is configured toengage and support a surface of the circuit board 424 (along with themechanical interaction of the protrusions 468 and circuit board 424),thus helping accommodate mechanical forces (e.g., stresses) at theinterfaces. In the illustrated embodiment, the securing portion 466includes a pair of protrusions 468. However, in other embodiments, moreor fewer protrusions are possible. The protrusions 468 include a lip 472that is configured to create a snap fit with recesses formed in thecircuit board 424, as will be described in detail below. In onealternative embodiment, the example securing portion 466 concept may beincorporated into the DC power connector 126 and the AC power connector128 illustrated in FIG. 2 . For instance, the securing portion 466 maybe integrally molded (e.g., via injection molding) with the overallexample DC power connector body 160 and the AC power connector body 170to provide enhanced integrity to the connections between the circuitboard 124 and the DC power connector 126 and the AC power connector 128.

FIG. 25 illustrates a cross-sectional view of the DC power connector 426according to one embodiment of the invention. The DC power connector 426includes a tooth 480 formed in each of the channels defined by the firstand second plugs 446, 448. Each tooth 480 can be integrally formed withthe body of the DC power connector 426. Each tooth 480 is configured asa pin alignment feature and can be dimensioned to engage a correspondingalignment feature formed in a pin (see, for example, notch 498 in FIG.27 ). Each tooth 480 is capable of facilitating a manufacturing processof the microinverter 420 by correctly orienting pins, such as the firstand second pins 486, 488 illustrated in FIG. 26 , rotationally relativeto the circuit board 424 within the DC power connector 426 prior tosecuring the DC power connector 426 to the circuit board 424. Forexample, the first and second pins 486, 488 may be oriented tofacilitate alignment and coupling of respective terminal ends of each ofthe first and second pins 486, 488 with a desired recess positioned onthe circuit board 424. The specific form factors of the cooperating pinalignment feature of the connector (e.g., tooth 480) and the alignmentfeature of the pin (e.g., notch 498) can take a variety of functionalforms, such as arcuate, beveled, angled, tapered, keyed, and the like,with each being configured to establish the desired relative positioningof the pin within the connector.

FIG. 26 illustrates components of the microinverter 420 including thecircuit board 424, the DC power connector 426, and the first and secondpins, 486, 488. The first and second pins 486, 488 each includerespective pin bodies 490, 492 and respective connection elements 494,496. The first and second pins 486, 488 are similar to the first andsecond pins 162, 164 of the DC power connector 126. Likewise, the pinbodies 490, 492 engage the DC power connector 426 similarly to the DCpower connector 126, and can be inserted proximate to the base 450. Inone embodiment, the first and second connection elements 494, 496provide a solder location when the DC power connector 426 is coupled tothe circuit board 424.

FIG. 27 illustrates the first and second pins 486, 488 seated in thechannels formed by the first and second plugs 446, 448. As brieflydescribed above, each of the first and second pins 486, 488 include anotch 498. Each notch 498 is configured as an alignment feature that canengage each tooth 480 to rotationally orient the first and second pins486, 488 within the DC power connector 426. Also as illustrated, each ofthe first and second connection elements 494, 496 extend through thenotch 434 formed in the body 430 of the housing 422. Likewise, thesecuring portion 466 extends through the notch 434 from the exteriorsurface 432 to the interior volume of the housing 422 to support andengage the circuit board 424, as well as help orient the first andsecond pins 486, 488 for electrical coupling to the circuit board 424.When the DC power connector 426 is secured to the housing 422, a portionof the notch 434 is seated in the groove 456 of the DC power connector426.

FIGS. 28 and 29 illustrate a front portion of the microinverter 420 ofFIG. 22 . As briefly described above, the curved surface 454 of the DCpower connector 426 has a similar shaped profile to the notch 434 formedin the body 430 of the housing 422. The corresponding profiles allow theDC power connector 426 to engage the housing 422. In some embodiments,the DC power connector 426 sealingly engages the housing 422. In someembodiments, the microinverter 420 can include a seal between the DCpower connector 426 and the housing 422 to provide a barrier between theexterior surface 432 of the body 430 and the interior volume. Also asdiscussed above, the base 450 includes a channel 458 that is dimensionedto receive the seal 440 so that the flat surface 452 can sit flush witha portion of the body 430 and the lid 436 can engage the body 430 andthe DC power connector 426 at the flat surface 452, as illustrated inFIG. 29 .

FIGS. 30 and 31 illustrate the DC power connector 426 secured andelectrically coupled to the circuit board 424. FIG. 30 in particularillustrates the DC power connector 426 secured and electrically coupledto the circuit board 424 and a portion of the lid 436 secured to thebody 430, thereby enclosing the circuit board 424 within the interiorvolume. FIG. 30 further illustrates the seal 440 positioned between thechannel 458 formed in the flat surface 452 of the DC power connector 426and/or the lid 436.

FIGS. 31 and 32 illustrate the DC power connector 426 secured to thecircuit board 424 and first and second connection elements 494, 496electrically coupled to the circuit board 424. As briefly described withrespect to the first and second pins 162, 164 of the microinverter 120,portions of the first and second connection elements 218, 232 can extendunder the circuit board 124 proximate to the bottom surface 154 of thecircuit board. The first and second pins 486, 488 include a similarconfiguration. Illustrated in FIG. 32 , portions 502 and 504 of thefirst and second connection elements 494, 496 extend below the circuitboard 424 proximate to a bottom surface 506 of the circuit board. Thefirst and second connection elements 494, 496 then extend throughrecesses formed in the circuit board 424, as can be seen in FIG. 31 .

FIG. 32 further illustrates that when the DC power connector 426 issecured to the circuit board 424, the mate surface 470 of the securingportion 466 is engaged with the bottom surface 506 of the circuit board424 and the protrusions 468 extend through the circuit board 424 andcreate a snap fit at the lips 472, as shown in FIG. 31 . In general, theengagement of the circuit board 424 with the securing portion 466 of theDC power connector 426 provides a rigid connection that can beestablished before the circuit board 424 is inserted into the housing422.

FIGS. 33 and 34 illustrate a connection pin 524 according to oneembodiment of the invention. In some embodiments, the connection pin 524can be used with either of the microinverters 120, 420, for example. Thepin 524 includes a pin body 526 that defines a pin body axis. Aconnection element 528 extends from the pin body 526 along the pin bodyaxis. The connection element 528 includes a terminal end 530 that isskewed relative to the pin body axis. In particular, the terminal end530 is bent approximately 90 degrees from the pin body axis. The pinbody 526 includes engagement tabs 532 that are spaced annularly aboutthe pin body 526 and fan out radially to create a ramped portion 534.The connection pin 524 can be used with a power connector and theengagement tabs 532 can provide an engagement feature so that theconnection pin 524 can only be moved through a channel of a powerconnector in a single direction.

FIGS. 35-40 illustrate a single DC power connector 550 according to oneembodiment of the invention. The single DC power connector 550 may beused with a variety of microinverters, such as with the microinverters120 and 420 described above. The single DC power connector 550 includesa plug 552 that is similar to the first plug 176 of the DC powerconnector 126. The single DC power connector 550 also includes a base554. As illustrated in FIGS. 35 and 36 , the base 554 includes a basesurface 556. The base surface 556 can engage and support a circuit board560 (see, for example, FIG. 40 ). The base 554 also includes a slot 564that extends into the base 554 perpendicular to the base surface 556.

As illustrated in FIG. 37 , the single DC power connector 550 isconfigured to receive a connection pin, such as the connection pin 524,or any other pin described herein or otherwise. The connection pin 524,which may define a male or a female coupling structure, can be insertedinto a channel (not shown) that extends through the plug 552. The singleDC power connector 550 can correspond to either one of a positive DCpower terminal or a negative DC power terminal. In some embodiments, asecond DC power connector 570 can correspond to the other of thepositive DC power terminal or the negative DC power terminal.

For example, FIG. 38 illustrates the single DC power connector 550 andthe second single DC power connector 570 exploded from a housing 576.The housing 576 includes first and second notches 578, 580 that have aprofile that corresponds to the bases 554 of each of the single DC powerconnectors 550, 570. When the single DC power connectors 550, 570 areengaged with the housing 576, the slot 564 can engage the correspondingnotch 578, 580 to flank a portion of a wall of the housing 576.Illustrated for example, in FIG. 40 , the housing 576 engages the base554 of the single DC power connector 550 at the slot 564. The engagementof the slot 564 with the notch 578 in the housing 576 positions the basesurface 556 at an appropriate height within the housing 576 so that thecircuit board 560 is supported by the base surface 556.

In some embodiments, during a manufacturing process, the terminal end530 of the connection pin 524 may be electrically coupled to the circuitboard 560 (e.g., via solder) and the base surface 556 can engage andsupport a bottom surface of the circuit board 560. Then the assembly ofthe circuit board and the DC power connector 550 can be inserted intoand secured to the housing so that the DC power connector 550 extendsoutside of the housing 576 via the notch. In other manufacturingprocesses, one or more pins are aligned with and seated at leastpartially within a body of a connector. A securing portion of theconnector body is engaged with a circuit board to align and support thecircuit board relative to the connector and the one or more pins. Theone or more pins are electrically coupled to the circuit board (e.g.,via a soldering operation). The completed assembly is then aligned andengaged with a receiving structure defined by a housing.

The discussion herein is presented for a person skilled in the art tomake and use embodiments of the invention. Given the benefit of thisdisclosures, various modifications to the illustrated embodiments willbe readily apparent to those skilled in the art, and the genericprinciples herein can be applied to other embodiments and applicationswithout departing from embodiments of the invention. Thus, embodimentsof the invention may be not intended to be limited to embodiments shown,but can be to be accorded the widest scope consistent with theprinciples and features disclosed herein. The detailed description is tobe read with reference to the figures, in which like elements indifferent figures have like reference numerals. The figures, which maybe not necessarily to scale, depict selected embodiments and may be notintended to limit the scope of embodiments of the invention. Skilledartisans will recognize the examples provided herein have many usefulalternatives and fall within the scope of embodiments of the invention.

Although the invention has been described and illustrated in theforegoing illustrative embodiments, it is understood that the presentdisclosure has been made only by way of example, and that numerouschanges in the details of implementation of the invention can be madewithout departing from the spirit and scope of the invention, which islimited only by the claims that follow. Features of the disclosedembodiments can be combined and rearranged in various ways.

The invention claimed is:
 1. A connector assembly configured for usewith at least one of an AC and a DC power interface of a powerconversion device, the connector assembly comprising: a circuit boarddefining a first surface and a second surface spaced apart from thefirst surface by a thickness; a power connector having a base configuredto be secured relative to the circuit board and defining a first channelextending through the power connector along a first channel axis; and afirst pin having a first pin body extending along a first pin axis and afirst connection element extending along the first pin axis from thefirst pin body to a first terminal end that is skewed relative to thefirst pin axis; wherein the first pin is at least partially seated inthe first channel; wherein the terminal end is configured toelectrically engage the circuit board; and wherein the first pinincludes a first alignment feature and the power connector includes apin alignment feature that is dimensioned to engage the first alignmentfeature to rotationally position the first terminal end relative to thecircuit board.
 2. The connector assembly of claim 1, wherein theterminal end is perpendicular to the first surface of the circuit board.3. The connector assembly of claim 1, wherein the terminal end extendsthrough the thickness of the circuit board.
 4. The connector assembly ofclaim 1, further comprising: a second pin having a second pin bodyextending along a second pin axis and a second connection elementextending along the second pin axis from the second pin body to a secondterminal end; wherein the second pin is at least partially seated in asecond channel defined by the power connector.
 5. The connector assemblyof claim 4, wherein each of the first pin and the second pin areelectrically coupled to the circuit board by a respective solder jointat the respective first and second terminal end.
 6. The connectorassembly of claim 1, further comprising: a housing defining an interiorvolume that encloses the circuit board and an exterior surface thatincludes a notch; wherein the power connector is secured to the housingproximate the notch; and wherein the first pin extends through thenotch.
 7. The connector assembly of claim 6, wherein the power connectorengages the housing to create a seal between the exterior surface andthe interior volume at the notch.
 8. The connector assembly of claim 6,wherein the housing includes a lid that engages a flat surface of thepower connector.
 9. The connector assembly of claim 8, wherein the flatsurface includes a groove that receives a seal.
 10. The connectorassembly of claim 6, wherein the notch includes a protrusion thatengages a groove formed in the power connector to secure the powerconnector to the housing.
 11. The connector assembly of claim 1, whereinthe first alignment feature is a notch and the pin alignment feature isa tooth.
 12. The connector assembly of claim 1, wherein the powerconnector includes a securing portion that is integrally formed with thepower connector and dimensioned to engage the circuit board to securethe power connector relative to the circuit board.
 13. The connectorassembly of claim 1, wherein the power connector is configured to beconnected to a solar module.
 14. The connector assembly of claim 1,wherein the first pin axis is parallel to the first surface of thecircuit board.
 15. The connector assembly of claim 1, wherein the firstchannel of the power connector extends parallel to the first surface ofthe circuit board.
 16. The connector assembly of claim 1, wherein thepower connector is rigidly connected to the circuit board.
 17. Theconnector assembly of claim 16, further comprising: a second powerconnector rigidly connected to the circuit board; and wherein the powerconnector is a DC power connector and is configured to be electricallycoupled to a DC power output and the second power connector is an ACpower connector and is configured to be electrically coupled to an ACpower interface.
 18. The connector assembly of claim 17, wherein the DCpower connector is configured to be connected to a solar module and theAC power connector is configured to be connected to a power grid. 19.The connector assembly of claim 17, wherein: the DC power connectordefines the first channel extending through the DC power connector alongthe first channel axis and the AC power connector defines a secondchannel extending through the AC power connector along a second channelaxis; and each of the first channel axis and the second channel axis areparallel to the first surface of the circuit board.
 20. A connectorassembly configured for use with at least one of an AC and a DC powerinterface of a power conversion device, the connector assemblycomprising: a circuit board defining a first surface and a secondsurface spaced apart from the first surface by a thickness; a DC powerconnector configured to be electrically coupled to a DC power output; anAC power connector configured to be electrically coupled to an AC powerinterface; at least one of the DC power connector and the AC powerconnector having a base configured to be secured relative to the circuitboard and defining a first channel extending through the at least one ofthe DC power connector and the AC power connector along a first channelaxis; and a first pin having a first pin body extending along a firstpin axis and a first connection element extending along the first pinaxis from the first pin body to a first terminal end that is skewedrelative to the first pin axis; wherein the first pin is at leastpartially seated in the first channel; and wherein the terminal end isconfigured to electrically engage the circuit board.
 21. The connectorassembly of claim 20, wherein the DC power connector is rigidlyconnected to the circuit board and the AC power connector is rigidlyconnected to the circuit board.
 22. The connector assembly of claim 20,wherein the DC power connector is configured to be connected to a solarmodule and the AC power connector is configured to be connected to apower grid.
 23. The connector assembly of claim 20, wherein: the DCpower connector defines the first channel extending through the DC powerconnector along the first channel axis and the AC power connectordefines a second channel extending through the AC power connector alonga second channel axis; and each of the first channel axis and the secondchannel axis are parallel to the first surface of the circuit board. 24.The connector assembly of claim 20, wherein the terminal end extendsthrough the thickness of the circuit board.
 25. The connector assemblyof claim 20, further comprising: a housing defining an interior volumethat encloses the circuit board and an exterior surface that includes anotch; wherein one or more of the DC power connector and the AC powerconnector is secured to the housing proximate the notch; and wherein thefirst pin extends through the notch.